A Practical Guide to Microparticle Fabrication: An Illustrated Review of Sixteen Methods

Selecting a microparticle fabrication method requires an understanding of payload compatibility, particle formation, and manufacturing constraints. This review summarizes these considerations and provides guidance on method selection. PubMed, Scopus, and Web of Science databases were searched up to February 2026, supplemented by Google Scholar searches. This structured narrative review compares 16 microparticle fabrication methods, examining their mechanisms, key formulation and process variables, material compatibility, particle properties, release behavior, scalability, and limitations. Representative patented methods are also listed to provide an additional informative technological context. Among the analyzed methods, interfacial dynamics, heat and mass transfer, payload partitioning, and carrier solidification help explain how processing conditions influence particle properties and release. Spray drying and coating are relatively well-established industrial processes. Droplet microfluidics and electrospraying enable precise control over particle size and architecture, though throughput and scale-up remain challenges. Whereas mild aqueous processing may help preserve the integrity of labile biomacromolecules, solvent- and melt-based techniques require careful control of residual solvents and thermal exposure. For long-acting delivery, particular attention must be paid to matrix tortuosity, the changing contributions of diffusion and degradation, and initial burst release. However, direct comparisons are difficult due to differences in formulation parameters and testing conditions. Method selection remains application-dependent. Payload stability, desired particle structure and release profiles, manufacturing constraints, and production scale must all be comprehensively considered. More consistent reporting and direct comparisons under relevant industrial conditions would provide stronger support for these decisions.